Abstract

This study evaluates the mechanical performance, material selection, and regulatory implications of polymer-based, 3D-printed firearm frames, focusing on their structural viability, production feasibility, and societal impact. Through a multidisciplinary literature review, we examine additive manufacturing methods, material properties of common polymers, cost analysis across various printing setups, and the ethical, legal, and forensic challenges posed by decentralized firearm production. Our review encompasses over forty years of scholarship, beginning with foundational work on weapon materials from 1982 (Harding, Weapons: An International Encyclopedia from 5000 BC to 2000 AD) and extending to the latest research on the proliferation of 3D-printed firearms, including a 2025 publication by Everytown Research & Policy (Printing Violence). Findings highlight the rapid evolution of additive manufacturing from traditional metalworking origins to modern polymer-based, low-cost firearm fabrication, revealing significant gaps in current safety standards, traceability, and global arms control frameworks. This paper underscores the urgent need for a balanced approach that combines technological innovation with robust regulatory and ethical safeguards to mitigate the risks associated with unregulated 3D-printed weaponry.